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iQ Series, Ultrasonic Hand Held Systems User’s Manual
Dukane Manual Part No. 403-583-00
Theory of Operation
Plastic welding is the most common application of
ultrasonic assembly. To perform ultrasonic plastic
welding, the vibrating tip is brought into contact with
one of the work pieces. Pressure is applied and ultrasonic
energy travels through the material generating frictional
heat at the contact point of the two parts. The frictional
heat melts a molded ridge of plastic on one of the pieces
and the molten material ows between the two surfaces.
When the vibration stops, the material solidies forming a
permanent bond.
Probe Conguration
A basic ultrasonic probe package consists of:
1. A probe which houses the transducer to convert the elec-
trical energy supplied by the generator into mechanical
vibrations.
2. A horn to transfer the mechanical vibrations from the
probe to the parts to be welded.
Optional components include special replaceable tips
which can be threaded on to the tip of the horn, and a
booster to amplify the mechanical vibrations of the horn.
A basic probe system is shown in Figure 6-1.
Normally a booster is not used with a probe as this
increases the length and weight and reduces its versatility.
The optional threaded titanium tip can be used when the
application calls for a staking prole or a pointed spot
weld. Replaceable tips are not commonly used in high–
volume production environments.
Standard
Horn
Probe
Tip
Custom
Horn
Figure 6–1 Probe, Horn and Tip
CAUTION
Never use a probe if the
cable insulating jacket is
cut or damaged in any way.
NOTE
For automated systems we recommend that
you use a booster with the probe as shown in
Figure 6-2. Read Dukane’s Application Note
#504 - Ultrasonic Acoustic Stack Mounting
Guidelines - found on our website at http://
www.dukane.com/us/DL_ApplData.asp